Interesting Clutch Issue

Discussion in 'Parallel Universe' started by mxbulldog, Sep 10, 2012.

  1. mxbulldog

    mxbulldog Braaaap!

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    On my recent trip up to Inuvik from Saskatchewan, I noticed my clutch freeplay adjustment started to tighten up. This is on a 2009 F800GS that now has around 26,000km. I had to loosen the cable a couple of times and recalled doing that once before the start of the trip as well. I am now out of adjustment on the cable. Normally, as the clutch wears you need to remove slack from the cable, but I am having to add more slack all of the time. It does seem to slightly tighten up as it gets up to operating temperature.

    Any thoughts as to what the problem might be? It is almost the end of the riding season here so i think I will be tearing into it to check the clutch plates and springs soon.
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  2. Indy Unlimited

    Indy Unlimited Long timer

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    The only thing that makes sense to me is that the fiber plates are breaking apart and the debris is stuck between the friction and drive plates causing the clutch engagement gap to grow.:1drink The other thing that could be going on is the clutch actuator cam is breaking off of the shaft causing sudden adjustment and tweaking. I have seen this on my buddies Husky TE610 and it works for a while and then you clutch actuation is completely gone.
    #2
  3. mxbulldog

    mxbulldog Braaaap!

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    That's so crazy it just might make sense...
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  4. MCMXCIVRS

    MCMXCIVRS Long timer

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    Nope, as it wears you lose slack. If you've run out of adjustment, you've pretty much also about run out of usable clutch.

    Get the new updated clutch plates and springs and keep more slack than was originally specified for the 09 model year. I don't recall what the new spec is off hand, but I run mine with tons of slack (6-7mm) and have had no problems. Have not had to readjust since the clutch replacement two years ago.
    #4
  5. mxbulldog

    mxbulldog Braaaap!

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    I've always run lots of slack... much more than recommended. Not much of a clutch abuser, I save that for the mx bikes. Going to order plates and springs and pull it apart in a couple weeks.
    #5
  6. vanbc

    vanbc Adventurer

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  7. Moptop

    Moptop Adventurer

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  8. Reaver

    Reaver Outta Here

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    OK, gotta give my two cents.

    My 09 has the same issue. Lots of free play but no further adjustment possible. Just did a 6500 km trip and it's still ok but has less play.

    After 09, BMW changed the cable length and the part number. Get the latest cable and the thin nut and you're good to go as long as your clutch still functions normally. I replaced a clutch because it had no more adjustment however all the plates and springs measured within spec. It was a customer warranty and shortly after that the new cable revision came out that would have fixed it.

    If you're in 6th gear under power, pull in the clutch a bit (without reducing throttle) then snap it out. If you feel the sudden jerk then the clutch is ok, if it's a smooth transition like you slowly let out the clutch then it's slipping and needs replacing.

    You could just get a thinner nut on the upper end of the adjuster for now.

    That's my plan, YMMV. A cable is cheaper and easier and you'll need it eventually anyway.
    #8
  9. mxbulldog

    mxbulldog Braaaap!

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    Interesting about the cable update. Thanks!

    No slippage at all with the clutch presently. I have been obsessing over that for the last 4000km. My new clutch plates and springs are at the stealership but I think I will inquire about the updated cable as well.
    #9
  10. Moptop

    Moptop Adventurer

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    Just got the bike back with the new upgraded clutch and longer cable.
    #10